Part 1

MANUAL TRANSAXLE ASSEMBLY (E350 TRANSAXLE)
OVERHAUL





1. REMOVE CLUTCH RELEASE FORK SUB-ASSEMBLY
a. Remove the clutch release fork sub-assembly with the clutch release bearing assembly from the manual transaxle case.
2. REMOVE CLUTCH RELEASE BEARING ASSEMBLY
a. Remove the clutch release bearing assembly and clutch release bearing hub clip from the clutch release fork sub-assembly.





3. REMOVE RELEASE FORK SUPPORT
a. Remove the clutch release fork support from the manual transaxle case.
4. REMOVE CLUTCH RELEASE FORK BOOT
a. Remove the clutch release fork boot from the manual transaxle case.
5. REMOVE SPEEDOMETER DRIVEN HOLE COVER SUB-ASSEMBLY
a. Remove the bolt and speedometer driven hole cover sub-assembly.
b. Remove the O-ring from the speedometer driven hole cover sub-assembly.





6. REMOVE SELECTING BELL CRANK ASSEMBLY
a. Remove the 2 bolts and selecting bell crank assembly from the manual transmission case.
b. Remove the shift & select lever bush from the selecting bell crank assembly.





7. REMOVE CONTROL SHIFT LEVER
a. Remove the nut and spring washer.





b. Using a brass bar and hammer, remove the shift outer lever lever lock pin.
c. Remove the control shift lever.





8. REMOVE CONTROL SHAFT COVER
a. Remove the 4 bolts, control shaft cover and gasket from the manual transmission case.





9. FIX MANUAL TRANSAXLE ASSEMBLY
a. Place the manual transaxle assembly on wooden blocks.





10. REMOVE LOCK BALL ASSEMBLY NO.1
a. Remove the lock ball assembly No.1 from the manual transmission case.





11. REMOVE MANUAL TRANSMISSION BREATHER PLUG
a. Remove the manual transmission breather plug and gasket.





12. REMOVE SHIFT & SELECT LEVER SHAFT ASSEMBLY
a. Remove the shift & select lever shaft assembly from the manual transmission case.





13. REMOVE BACK UP LAMP SWITCH ASSEMBLY
a. Remove the back up lamp switch assembly and gasket from the manual transmission case.





14. REMOVE MANUAL TRANSMISSION FILLER PLUG
a. Remove the manual transmission filler plug and gasket from the manual transmission case.





15. REMOVE DRAIN (MTM) PLUG SUB-ASSEMBLY
a. Remove the drain (MTM) plug sub-assembly and gasket from the manual transmission case.





16. REMOVE MANUAL TRANSMISSION CASE COVER SUB-ASSEMBLY
a. Remove the 10 bolts and manual transmission case cover from the manual transmission case.





17. REMOVE MANUAL TRANSMISSION OUTPUT SHAFT REAR SET NUT
a. Engage two gears simultaneously to lock the transmission.





b. Using SST and a hammer, unstake the manual transmission output shaft rear set nut.
SST 09930-00010





c. Using SST, remove the manual transmission output shaft rear set nut from the output shaft.
SST 09229-55010
d. Disengage the two gears.





18. INSPECT 5TH GEAR THRUST CLEARANCE
a. Using a dial indicator, inspect the 5th gear thrust clearance.
Standard clearance: 0.10 to 0.65 mm (0.0039 to 0.0256 inch)
If clearance is out of specification, replace the transmission clutch hub No.3, 5th gear or input shaft rear radial ball bearing.





19. INSPECT 5TH GEAR RADIAL CLEARANCE
a. Using a dial indicator, inspect the 5th gear radial clearance.
Standard clearance: 0.009 to 0.050 mm (0.0004 to 0.0020 inch)
If clearance is out of specification, replace the 5th gear, 5th gear needle roller bearing or input shaft.





20. REMOVE TRANSMISSION CLUTCH HUB NO.3
a. Using 2 screwdrivers and a hammer, remove the transmission clutch hub No.3 shaft snap ring from the input shaft.

HINT: Cover with a shop rag to keep the snap ring from flying.





b. Remove the shift fork set bolt from the gear shift fork No.3.





c. Using SST, remove the transmission clutch hub No.3, transmission hub sleeve No.3 and gear shift fork No.3 from the input shaft.
SST 09950-30012 (09951-03010, 09953-03010, 09954-03010), 09950-50013 (09957-04010), 09950-60010 (09951-00280)





21. REMOVE 5TH GEAR
a. Remove the 5th gear from the input shaft.





22. REMOVE 5TH GEAR NEEDLE ROLLER BEARING
a. Remove the 5th gear needle roller bearing from the input shaft.





23. REMOVE 5TH DRIVEN GEAR
a. Using SST, remove the 5th driven gear from the output shaft.
SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09957-04010), 09950-60010 (09951-00180, 09955-03011), 09950-50013





24. REMOVE BEARING RETAINER REAR (MTM)
a. Using a torx socket wrench (T45), remove the 7 torx screws and bearing retainer rear (MTM) from the manual transmission case.





25. REMOVE OUTPUT SHAFT REAR BEARING SHIM
a. Remove the output shaft rear bearing shim from the output shaft.





26. REMOVE INPUT SHAFT REAR BEARING SHAFT SNAP RING
a. Using a snap ring expander, remove the input shaft rear bearing shaft snap ring from the input shaft.





27. REMOVE SHIFT FORK SHAFT SHAFT SNAP RING
a. Using 2 screwdrivers and a hammer, remove the shift fork shaft shaft snap ring from the gear shift fork shaft No.1.

HINT: Cover with a shop rag to keep the snap ring from flying.





b. Using 2 screwdrivers and a hammer, remove the shift fork shaft shaft snap ring from the gear shift fork shaft No.2.

HINT: Cover with a shop rag to keep the snap ring from flying.





28. REMOVE REVERSE IDLER GEAR SHAFT BOLT
a. Remove the reverse idler gear shaft bolt and gasket.
29. REMOVE CLUTCH TUBE BRACKET
a. Remove the bolt and clutch tube bracket.





30. REMOVE MANUAL TRANSMISSION CASE
a. Remove the 3 bolts from the manual transaxle case side.





b. Remove the 14 bolts from the manual transmission case side.
c. Tapping with a plastic hammer, remove the manual transmission case.